Automated Self-Sealing Diffuser and Related Method of Use

ABSTRACT

The invention is directed to an automated self-powered HVAC diffuser system having a central control unit that determines room-specific temperature. The system fits within a standard HVAC diffuser through a housing rod having a front side, a rear side and a middle portion. A central rod perpendicularly attached to the front side of the housing rod maintains an expandable damper fan through a damper head. A micro-motor attaches to the expandable damper fan through a drive shaft which expands and contracts the expandable damper fan to regulate conditioned air flowing out of the HVAC diffuser based upon instructions from the central control unit. In addition, a sensory board affixed to the rear end of the housing rod includes an infrared that communicates with the central control unit. A rechargeable battery stores energy, created by an airflow prop rotating through contact with conditioned air, creates electricity via a generator.

FIELD OF THE INVENTION

This invention is directed toward an automated self-sealing diffuser foruse in an HVAC system to ensure more efficient and regulated control oftemperature within a residential or commercial space.

BACKGROUND OF THE INVENTION

Under normal operating conditions, residential and commercial heating,ventilating and air conditioning (HVAC) systems include a series ofducts to ensure uniform distribution of conditioned air, consistentstatic pressure and unrestricted air-flow. To assist in thisdistribution, venting dampers, registers and differs are placed attermination points within the duct system to distribute airflow. Indoorthermostats measure the temperature inside the residential or commercialfacility, which will send an electrical signal to the HVAC system. Thistemperature reading signals the HVAC system to condition the air byheating or cooling it to achieve a desired temperature range.

One key issue with current HVAC systems is that while the duct system isdesigned to ensure uniform conditioning of air throughout the facility,there are many different factors that lead to large temperaturedifferentials throughout the facility. This can include the sun warmingone side of the home or high winds causing cooling a portion of theresidence. Sun angles, time of year (seasons), building construction,insulation values (walls & windows), weather conditions, location ofstructure are also a factor. Further, an addition to an older home orbuilding a home to meet the unique topography of an area may causeuneven cooling or heating despite a high quality and efficient HVACsystem.

Another limitation to regulating multiple rooms served by an HVAC systemis that each room is not regulated, and there may be only a few zones.Each zone may have a thermostat, which senses the temperature of thatparticular zone. However, for the same reasons addressed above, this maystill lead to temperature swings as each room's temperature within thezone is not monitored. This is occurring while the HVAC system isattempting to satisfy the thermostat within that zone.

The end result of this uneven heating and cooling leads to the overallinefficiency of the HVAC system. This in turn leads to higherelectricity costs, larger demands on the HVAC system and a shorterlifespan of the components (and increased replacement costs). In oneexample, overnight use of an HVAC system may require a zone within thesecond floor of a home to overheat the first zone on the first floor, toensure a comfortable sleep environment requiring additional energyexpenditure.

There have been several attempts to create electro-mechanical dampersplaced within duct systems to better distribute conditioned air throughthe HVAC system. While these electromechanical dampers help direct airinto rooms that require more or less airflow, these dampers areexpensive and must be installed when the home is built (or when there isa large renovation). In most cases the added cost for such a system isgreater than the savings during the life of the (HVAC) system. Inaddition, this method is usually very general and not specific to eachroom or external conditions.

While some wireless methods have been created to assist in damping thevarious ceiling diffusers within an HVAC system, these require batteryoperated thermostats rigidly attached to wall registers and ceilingdiffusers—which also reduces cost savings. Moreover, while these systemsappear to have an advantage, their small battery lives and frequentmaintenance make them less practical. More specifically, the life of thebatteries are extremely limited due to the thermostat transmitting aradio frequency signal and the receiver and motor section on the dampervent, which continually must be on receiving mode and utilizing motorand armatures to open and close vent.

In other systems, a fan blade or prop is mounted on a small generator inwhich the air flow within the duct system turns the fan and in turncharges the batteries. This method is an improvement, however, duringthe seasons of spring and fall when the system is usually dormant orvacation homes in which the system may sit idol for long periods oftime, the batteries will deplete to unusable levels rendering the systemuseless. In addition, these methods are used to limit the airflow to acertain location and not control the entire (HVAC) system or many otherfactors which effect efficiency.

Current statistics show that some fifty percent of a residential orcommercial building expense is the direct result of the HVAC system. Asshown above, little progress has been shown to create efficientretrofitted dampeners that will allow improved efficiency of existingduct work in a manner that will actually lead to saving money, energyand resulting fuel. With the growing interest in energy savings,reduction of carbon emissions and increasing energy efficiency—there isa need in the art for an improved damper system to allow more regulatedand controlled per-room air heating and cooling.

SUMMARY OF THE INVENTION

This invention is directed to an automated self-powered HVAC diffusersystem that can fit into any existing HVAC diffuser. A single HVACdiffuser system may be placed in each room, zone or area to betterregulate the temperature throughout a period of time (hours of the day,day, week or month). Each room is equipped with a central control unit,which is supplied energy by an energy supply (a 110V standard plug, byway of example). The central control unit measures room conditions,including temperature and humidity and measures whether they fall withina desired range. The diffuser system may be affixed within the standardHVAC diffuser via a housing rod having a front side, a rear side, and amiddle portion. A central hollow rod is perpendicularly attached to thefront side of the housing rod proximate the middle portion.

An expandable damper attaches to the central rod via a damper head. Theexpandable damper comprises an upper frame, a lower frame and bellows.Preferably, the distal ends of the bellows include self-sealing gasketsthat contact the walls of the diffuser to reduce the flow of circulatedair out of the diffuser. The expandable damper moves about the centralrod via a micro-motor, which expands and contracts the expandable damperthrough a drive shaft to regulate the amount of conditioned air flowingout of the HVAC diffuser based upon instructions from the centralcontrol unit.

In addition, a sensory board maybe affixed proximate the rear end of thehousing rod proximate the middle portion having an infrared receivercapable of communicating with the central control unit. A generatorhaving an airflow prop creates electricity to supply a rechargeablebattery, through rotating the airflow proper due to contact withconditioned air flowing out of the diffuser. The sensory board furthercomprises an antenna, a circuit board and dip-switches.

Information may be reported from the sensory board through the antennato an energy management system. The energy management system calculatesenergy efficiencies and related savings through use of the diffusersystem as well as total energy consumption within a home.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the invention, reference is made to thefollowing detailed description, taken in connection with theaccompanying drawings illustrating various embodiments of the presentinvention, in which:

FIG. 1 is a block diagram illustrating salient components of oneadvanced damper assembly according to the teaching of the presentinvention;

FIG. 2 illustrates an energy management system;

FIG. 3 illustrates an advanced HVAC damper in an open position;

FIG. 4 illustrates the advanced HVAC damper in a closed position; and

FIG. 5 is a flow chart showing one preferred method of using thediffuser system to increase energy efficiency.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will now be described more fully hereinafter withreference to the accompanying drawings, in which preferred embodimentsof the invention are shown. This invention may, however, be embodied inmany different forms and should not be construed as limited to theembodiments set forth herein. Rather, these embodiments are provided sothat this disclosure will be thorough and complete, and will fullyconvey the scope of the invention to those skilled in the art. Likenumbers refer to like elements throughout.

This invention helps solve many of the problems of current HVAC systemsto ensure more regulated and efficient use of conditioned air. Morespecifically, embodiments of the invention allow for a retrofitting oftraditional HVAC diffusers without requiring an overhaul of existingducting system. Through the use of wireless and infrared technology,coupled with advanced controls, a quick and efficient instillation ofthe assembly can be done by any user (not necessarily an HVAC trainedprofessional). The resulting system helps provide a more uniform andcontrolled circulation, use and enjoyment of conditioned air within eachspecific room, zone or area of a commercial or residential abode. Inaddition, the controls are designed to allow different pulls from thecentral HVAC system, in order to address temperature changes related tosun exposure, topography conditions and the unique layout of the home oroffice. The end result is more consistent and desired temperatures, lesswaste of conditioned air (either hot or cold), less energy expenditureand longer life-span of the overall HVAC system.

Overall Components

FIG. 1 illustrates, by way of example, the salient components of theadvanced diffuser system 100 contemplated by the invention, for insuringmore uniform and regulated per-room distribution of conditioned air.While FIG. 1, illustrates one assembly based upon the teachings of thepresent invention, one of ordinary skill in the art of HVAC systems willquickly realize other orientations and additional/alternative componentsthat could also be used to allow for more efficient use of HVAC systemswithout the need to remove or replace the existing ducting work.

As shown, the diffuser system 100 includes a diffuser assembly 110, acentral energy management system 200, an energy supply 300, aprogrammable control unit 400, a hand held control 500 and an infraredreceiver 600. The system is both portable and scalable, meaning thatadditional energy supplies 300, programmable control units and infraredreceivers 600 can be placed in multiple zones, rooms, or areas of aresidential or commercial facility.

As further shown in FIG. 1, one embodiment of the invention includes anenergy supply 200 that provides electricity to a programmable controlunit 300. Each energy supply 200 may be connected to a standard electricjack found within the home or commercial facility. This allows thediffuser system 100 to be installed without need of a professionalelectrician. Likewise, this system eliminates the need for a rewire of aroom's electricity.

Preferably, for each zone or room of the home or residential facilitydesired to be regulated, the invention contemplates placement of aprogrammable control unit 300 (again powered by an energy supply 200).While the programmable control unit 300 may take various forms, itpreferably includes both a temperature and humidity sensor.

Likewise, the programmable control unit 300 should be capable ofcommunicating directly with a hand held controller 500 as well as aninfrared receiver 600. If the temperature within the room falls outsidea desired range (by either the user, the hand controller 500, or thecentral energy management system 200), the central control unit 300 willreport this information (via the infrared receiver 600) to make changesvia the diffuser assembly 110 (open and/or close the diffuser)

As further shown in FIG. 1, the invention contemplates how each zone orroom may include a hand controller 500. This hand controller 500 allowsthe user to physically direct the temperature within that individualroom—as well as make changes to that room's temperature during periodsof use. This allows for more uniform and regulated per room usage of theHVAC System 290. The hand controller 500 may be placed in a cradle(located on a wall) positioned within each individual room or zone.

As illustrated, the hand controller 500 communicates with the centralcontroller 400, as well as the central energy management system 200 andthe infrared receiver 600 (and accordingly the diffuser assembly 110).Preferably, the hand controller 500 includes a receiver, a processor, aninternal memory device as well as an internal power supply—which maytake the form of a battery.

The Central Energy Management System

The central energy management system 200 shown in FIG. 1 and FIG. 2represents the core of this energy saving technology. Such system 200not only communicates with the HVAC system, but also receivedinformation from any ancillary devices such as solar panel arraysattached the home's roof, a depository of propane (or a natural gassupply), or a cogeneration system within the home. Such communicationsallows for a comprehensive energy analysis for the facility, anddetermines not only energy use across all energy sources, but alsodetermines efficiencies as well as energy savings through using thediffuser system 100.

As shown in FIG. 1, the energy management system 200 communicatesdirectly with each programmable control unit 400, every hand heldcontrol 500 and the infrared receiver 600 within each room or area. Bydirectly communicating with the infrared receiver 600, the energymanagement system 200 thus indirectly communicates with each diffuserassembly 110.

While FIG. 1 illustrates the placement and points of communication withthe energy management system 200, FIG. 2 illustrates, by way of example,one specific functionality. As shown, the energy management system 200communicates with any available solar system panel array 260, propanegas supply 270 and HVAC System 280 accessible by the residentialfacility or home. This allows for a comprehensive view of the totalenergy consumption by the home (or facility), as well as the percentageof electricity, gas and solar consumed. As described previously, theenergy management system 200 likewise communicates with the diffusersystem 100 to ensure proper distribution of conditioned air from the HVAsystem 280 (or any related co-generation system).

As further shown in FIG. 2, the energy management system 200 includes atouchscreen display 210 which allows a user to access a variety ofinformation relating to overall efficiency of the diffuser system 100,as well as other energy related systems. Such information includesoverall energy consumption, peak energy times, and diagnostic data. Thetouchscreen display 210 also allows the user to program the preferredtemperature of each room in which a diffuser assembly 110 isplaced—which can be programmed out per hour of day, week or month.

Apart from the touchscreen display 210, the energy management system 200also includes two display windows 220 and 230. As further shown in FIG.2, the first display window 220 provides a calculation as to the totaldollar figure of energy consumed within a specified time period.Conversely, the second display window 230 reports the total amount ofenergy (in kilowatts) expended by the residential facility. Thesecalculations are made through a central processor 201, memory unit 202and internal power supply 203 contained within the energy managementsystem 200.

Optionally, the energy management system 200 may include two or morepush bottoms 240 and 250. Both push buttons 240 and 250 select the timeperiod desired to report the total amount of energy consumed, as well asthe total costs associated with energy use. For example, by pressing thefirst push button 240, the first display window 220 will report thetotal energy savings and/or energy consumer in a dollar figure per day,week month or year. Likewise, employing the second push button 250 shallallow the second display window 230 to report kilowatts, propane pounds(lbs) natural gas expenditures and/or fuel oil used or consumed during agiven day, week, month or year.

The invention further contemplates a plurality of various reportinglights 290. These reporting lights 290 illuminate to report if thediffuser system 100 is providing for temperature savings, humiditysavings and related metrics.

The Diffuser Assembly

Both FIG. 3 and FIG. 4 illustrate, by way of example, the salientcomponents of one preferred diffuser assembly 110. First turning to FIG.3, the diffuser assembly 110 fits within the normal shape andconfiguration of a common HVAC diffuser 111 found within a commercial orresidential facility. This allows easy retrofitting of each diffuser 111within a desired room, zone or area of the home.

This is accomplished by a housing rod 120 that secures directly to thediffuser 111. The housing rod 120 is positioned parallel to the diffuseropening 112. The housing rod 120 includes a first end 121, a second end122 and a middle portion 123. In addition the housing rod 120 includes afront side 124 and a corresponding rear side 125. A first screw 126affixes the first end 121 of the housing rod 120 to the diffuser.Correspondingly, a second drew 126 affixes the second end 121 of thehousing rod 120. This allows the diffuser system 110 to essentiallyfloat within the core of the housing rod 120.

Perpendicularly attached to the front side 124 (proximate the middleportion 123) of the housing rod 120 is a central hollow rod 130. Thehollow rod 130 maintains three primary components of the diffuser system110: the expandable damper fan 140, the micro motor 150 and the driveshaft 160. All three components (140, 150 and 160) work to control theamount and quantity of conditioned air exiting the diffuser 111.

The expandable damper fan 140 functions to open and close the diffuseropening 112. As shown in FIG. 3, the expandable damper fan 130 mayinclude an upper frame 131 and a lower frame 142 that pivot about adamper head 143 affixed to the central hollow rod 130. Positionedbetween both frames 142 and 143 is a series of bellows 144 suspendedabout the hollow rod 130 through use of various rivets 145. Positionedat the distal ends 146 of the bellows 144 is a series of self sealinggaskets 147. These self-sealing gaskets 147 help create a contact point148 between the expandable damper fan 140 and the walls of the diffuser111.

As further shown in FIG. 3, by pivoting away from the central hollow rod130 both frames 141 and 142 may contact the outer walls of the diffuser111 to close the diffuser opening 112. Correspondingly, by contractingthe frames 141 and 142 toward the central hollow rod 130 the diffuser111 is opened to allow the flow of conditioned air outside of thediffuser opening 112. In turn, when expanding the frames 141 and 142 thevarious rivets 145 maintain the integrity of the bellows 144 to ensureproper closure and opening of the passageway within the diffuser 111 toallow flow of conditioned air.

As shown in FIG. 4, the contraction or expansion of the various frames141 and 142 of the expandable damper fan 130 is effectuated through useof a micro motor 150 and drive shaft 160. By engaging the micro motor150 to pull the drive shaft 160 away from the housing rod 120, this willcause the frames 141 and 142 to expand. Likewise, pushing the draftshaft 160 toward the housing rod 120 will cause the frames 141 and 142to contract.

In addition, the diffuser system 110 also includes various componentspositioned about the rear side 125 of the housing rod 120. As shown inboth FIG. 3 and FIG. 4, there are three primarily components on thisside of the housing rod 120: a sensory board 170, a power generator 180and an airflow prop 190. First, the sensory board 180 preferablyincludes and houses the infrared receiver 600. Accordingly, the sensoryboard 180 receives instructions from the hand controller 500, thecentral controller 400, and potentially the energy management center200. Preferably, the sensory board 170 may include a power supply 171 inthe form of a rechargeable lithium ion (or alternatively a nickelcadmium) battery 172. In addition, the sensory board 170 may include acircuit board 173, an antenna 174 and dip switches 175.

Attached to the sensory board 170 is a generator 180 which helps createelectricity to supply power to the battery 172. The generator 180connects to an airflow prop 190. Through the normal flow of air withinthe diffuser 111 (when the expandable damper fan 140 is open) theairflow prop 190 will spin, causing rotation within the generator 180and the creation of electricity. Accordingly, the diffuser system 110creates its own power through the natural flow of air—without need forrewiring the existing HVAC system 290. Put another way, the generator180 (via rotation of the airflow prop 190) creates its own electricityto later power the micro motor 150 and drive shaft 160 for purposes ofexpanding or contracting the expandable damper fan 140.

Method of Use

This invention is further directed to a method of using a diffusersystem 110 in combination with the programmable control unit 400, handcontroller 500 and the energy management center 200 to improve theefficiency of an existing HVAC system 290. FIG. 5 illustrates, by way ofexample, one preferred method to employ the diffuser system 100. Themethod first starts (at 700) by having the central control unit 400measures (at 710) the temperature and humidity of a particular room orzone. Typically, the central control unit 400 (either directly orthrough the hand held controller 500) has a pre-set temperature rangethat is desired for that particular room or zone.

The central control unit 400 next determines (at 720) whether roomconditions are within the present range. If such temperature andhumidity measures are within range, then the method recycles (to step710). Otherwise, the method next wirelessly sends (at 740) instructionsto the infrared receiver 600 located within the diffuser system 110.Alternatively, a user can manually instruct (at 730) the infraredreceiver 600 through the hand held controller 500 in order to change thetemperature within the room.

Regardless of whether the central control unit 400 automatically (or ifthe user manually instructs via the hand held controller 500), theinfrared receiver 600 will instruct (at 750) the sensory board 170 totell the micro motor 180 to engage drive shaft 160. In turn, the driveshaft 160 will contract (at 760) both the upper and lower frames 142 and143. This will result in reducing the size of the bellows 144 andtherefore reducing the cross sectional area of the expandable damper fan200. This will cause conditioned air to exist (at 770) the diffuser 111which will in turn cool the desired room, zone or area of theresidential or commercial facility for a period of time.

After conditioned air passes through the diffuser 111 to cool or heatthe room to a desired temperature, the central control unit 400 willrecheck (at 780) the room conditions—including temperature and humidity.The central control unit 400 will recheck (at 785) the temperature andother conditions within the room or area. After making thisdetermination, the central control unit 400 will report this informationback to the infrared receiver 600 positioned within the diffuser system110. If the temperature is still outside of the desired range, theexpandable damper fan 200 shall remain open to allow additionalconditioned air to pass through the diffuser 111.

However, if the temperature falls within the acceptable range, then thesensory board 170 shall instruct (at 790) the drive shaft 180 to expandboth frames 142 and 143 and increase the surface area of the bellows790. This in turn will cause the energy management center 200 to sealand close off the passage way within the diffuser 111—such thatconditioned air will not pass into that room, zone or area. Informationis then reported (at 795) to the central energy management system200—which may in turn calculate energy savings and other efficiencies.

The system may then report (at 710) based upon any preprogrammedtemperature profiles within a given day, week or month stored in thecentral control unit 400.

1. An automated self-powered HVAC diffuser system comprising: a centralcontrol unit that determines room-specific conditions, includingtemperature; a housing rod having a front side, a rear side and a middleportion, wherein the housing rod is dimensioned to be affixed within anopening of a standard HVAC diffuser; a central rod perpendicularlyattached to the front side proximate the middle portion of the housingrod; an expandable damper fan attached to the central rod through adamper head; and a micro motor attached to the expandable damper fanthrough a drive shaft which expands and contracts the expandable damperfan to regulate conditioned air flowing out of the HVAC diffuser basedupon instructions from the central control unit.
 2. The diffuser systemof claim 1, further comprising: a sensory board affixed proximate therear end of the housing rod proximate the middle portion, the sensoryboard including an infrared receiver capable of communicating with thecentral control unit; a generator having an airflow prop; and arechargeable battery which stores energy created by the airflow proprotating through contact with conditioned air and creating electricityvia the generator.
 3. The diffuser system of claim 2, wherein thesensory board further comprises an antenna, a circuit board anddip-switches.
 4. The diffuser system of claim 3, further comprising andenergy management system wherein information is reported from thesensory board through the antenna to the energy management system. 5.The diffuser system of claim 4, wherein the energy management systemcalculated energy efficiencies and related savings through use of thediffuser system as well as total energy consumption within a home. 6.The diffuser system of claim 1, wherein the housing rod has a first endand a second end such that the housing rod is affixed to the diffuseropening through a first screw affixed to the first end and acorresponding second screw affixed to the second end.
 7. The diffusersystem of claim 1, wherein the expandable damper comprises an upperframe, a lower frame and bellows there between.
 8. The diffuser systemof claim 7, wherein distal ends of the bellows include self-sealinggaskets which contact walls of the diffuser to reduce the flow ofcirculated air out of the diffuser.
 9. An automated self-powered HVACdiffuser system comprising: a central control unit that determinesroom-specific conditions, including temperature; a housing rod having afront side, a rear side and a middle portion, wherein the housing rod isdimensioned to be affixed within an opening of a standard HVAC diffuser;a central rod perpendicularly attached to the front side proximate themiddle portion of the housing rod; an expandable damper fan attached tothe central rod through a damper head; a micro motor attached to theexpandable damper fan through a drive shaft which expands and contractsthe expandable damper fan to regulate conditioned air flowing out of theHVAC diffuser based upon instructions from the central control unit; asensory board affixed proximate the rear end of the housing rodproximate the middle portion, the sensory board including an infraredreceiver capable of communicating with the central control unit; agenerator having an airflow prop operable therewith, the prop rotatingthrough contact with conditioned air and creating electricity via thegenerator; and a rechargeable battery which stores energy generated bythe airflow prop.
 10. The diffuser system of claim 9, wherein thesensory board further comprises an antenna, a circuit board anddip-switches operable therewith.
 11. The diffuser system of claim 10,wherein information is reported from the sensory board through theantenna to an energy management system.
 12. The diffuser system of claim11, the energy management system calculated energy efficiencies andrelated savings through use of the diffuser system as well as totalenergy consumption within a home.
 13. The diffuser system of claim 9,wherein the housing rod has a first end and a second end such that thehousing rod is affixed to the diffuser opening through a first screwaffixed to the first end and a corresponding second screw affixed to thesecond end.
 14. The diffuser system of claim 9, wherein the expandabledamper comprises an upper frame, a lower frame and bellows therebetween.
 15. The diffuser system of claim 14, wherein distal ends of thebellows include self-sealing gaskets which contact walls of the diffuserto reduce the flow of circulated air out of the diffuser.
 16. A methodof using a diffuser system in combination with a central control unit toimprove efficiency of an existing HVAC system, the method comprising thesteps of: (a) measuring a room's temperature through a central controlunit; (b) sending a signal to an infrared receiver within the diffusersystem if the room temperature falls outside a desired range; (c)commanding a micro motor to engage a drive shaft, through instructionsreceived by a sensory board from the infrared receiver, the drive shaftbeing engaged with an expandable damper fan attached to a central rodthrough a damper head; wherein the central rod is perpendicularlyattached to a housing rod which is affixed to an existing HVAC diffuser;and (d) constricting the expandable damper fan through the drive shaftin order to allow conditioned air to exist the HVAC diffuser for aperiod of time in order to change the room temperature.
 17. The methodof claim 16, further comprising the steps of: (e) rechecking the roomtemperature through use of the central control unit; (f) instructing thedrive shaft to expand the expandable damper fan if the room temperaturefalls within an acceptable temperature; (g) restricting the flow ofconditioned air through the HVAC diffuser; and (h) reporting informationto a central energy management system.
 18. The method of claim 17,further comprising the step of: (i) calculating energy efficiencies andrelated savings from data reported by the diffuser system to the energymanagement system, including but not limited to energy savings and totalenergy consumption within a home.
 19. The method of claim 16, whereinthe expandable damper comprises an upper frame, a lower frame andbellows attached thereto.
 20. The method of claim 19, wherein distalends of the bellows include self-sealing gaskets which contact walls ofthe diffuser to reduce the flow of circulated air out of the diffuser.